SCOPE OF WORK TURBO GEN SERVICES

(SOW) (TGS)

Title: Supply of High Pressure Cleaning SOW Unique Identifier: N/A

Alternative Reference No.: N/A

Area of Applicability: Eskom Rotek

Industries (ERI) SOC Ltd.

Document Type: Scope of Work (SOW)

Revision: 0

Total No. of Pages: 8

Next Review Date: N/A

Classification: Controlled Disclosure

Compiled by:

________________

Tumelo Mpete Date: 20/07/2022

Senior Service Engineer

Functional Responsibility:
Accepted by:
________________ ________________

Angelique Geldenhuys Date: 02/08/2022 Ridge Mabotja Date: 02/08/2022

Acting Chief Engineer Senior Project Manager
Approved by:
_________________________

Reinaldo Da Veiga Date: 5/8/2022

Engineering Manager

Page 1 of 8
Contents
1. OBJECTIVES ........................................................................................................................ 3
2. GENERAL REQUIREMENTS ................................................................................................. 3
3. SCOPE OF WORK (SOW) .................................................................................................... 5
4. SAFETY REQUIREMENTS .................................................................................................... 5
5. SHEQ REQUIREMENTS ....................................................................................................... 6
6. KEY PERFORMANCE INDICATORS ...................................................................................... 7
7. TECHNICAL EVALUATION................................................................................................... 8
1. OBJECTIVES

Scaling / Sludge build-up of pipes and tubes has been a major problem across Eskom Power
Stations, particularly with the relatively poor cooling water quality, poor flows and carryover
of sludge/debris to supplied components. High pressure water jetting has been identified as a
means of removing scales / sludge from the internal surfaces of tubes.
This document is drafted to select & place a contract with external service providers who are
able to perform High Pressure Cleaning of oil pipes and tubes.

2. GENERAL REQUIREMENTS

2.1 HIGH PRESSURE WATER JETTING (HPWJ) REQUIREMENTS FOR

CONDENSER AND HEAT EXCHANGER TUBING INCLUDING OIL PIPES

2.1.2 ACCEPTANCE CRITERIA

The internal surfaces of all tubes shall be cleaned by means of High Pressure Water Jetting
(HPWJ). The acceptance criteria is that all scale shall be removed from the internal surfaces
of the tubes, i.e. the entire internal tube surface of all the tubes shall be completely cleaned to
a uniform metallic colour with no traces of corrosion product or other scales and deposits.
This shall be validated by means of high resolution endoscope inspection and / or destructive
analysis of “cleaned tube” where applicable. Non achievement of the aforementioned
acceptance criteria shall be considered as non-performance with respect to the contract.

2.1.2 MINIMUM EQUIPMENT REQUIREMENTS

For tubes with an internal diameter of 20.5 mm up to 25 mm, the minimum nozzle flow rate
shall be 50 litre/min at 1 000 bar working pressure. For tubes with an internal diameter
between 15 and 20.5 mm the minimum nozzle flow rate shall be 33 litre/min at 1 000 bar
working pressure.
Rotating tube cleaning nozzles with multiple radial water jets or polishing nozzles shall be
used. The cleaning nozzles shall be obtained from a recognised HPWJ equipment supplier
including technical datasheets, providing technical information for a range of nozzle sizes,
shall be available for all the types of nozzles used on site. The maximum pressure rating of
the nozzle shall be 1 035 bar or 15 000 psi. Nozzles with a higher pressure rating are not
acceptable.
A technical data sheet shall be provided for the HPWJ pumps. The HPWJ pump shall
maintain a minimum continuous working pressure of 1 000 bar at a flow rate of 50
litre/minute. This requirement assumes one pump will supply one cleaning nozzle. If a single
pump is to supply more than one nozzle simultaneously, the pump shall maintain a minimum
continuous working pressure of 1 000 bar and a minimum volume flow of 50 (litre/min) per
each of the cleaning nozzles attached simultaneously to the pump.
The nozzles shall travel the full length of all the tubes.
The HPWJ flexible hose from the foot valve to the tube cleaning nozzle shall have a
minimum internal diameter of 6 mm for tubes with an internal diameter between 15 and 20.5
mm. For tubes with an internal diameter of more than 20.5 mm, the HPWJ flexible hose from
the foot valve to the tube cleaning nozzle shall have a minimum internal diameter of 7 mm.
The maximum hose length is the condenser tube length plus an additional 7 m. If the tube
length is more than 12 meters, the tubes shall be cleaned from both ends to avoid excessive
long hoses. The foot valve shall be positioned in the waterbox. The minimum number of
hoses available on site for the main and BFPT condensers are 4 and 2 respectively.
The flexible hose from the pump outlet to the foot valve shall have a minimum internal
diameter of 10 mm.
The Contractor shall make provision for a reasonable set/number of spare equipment and
tooling, particularly, nozzles, hoses, couplings, all wear and tear parts such as seals etc. These
spares shall be available on site. In the event of HPWJ Pump breakdown then repair or
suitable replacement shall be affected within 2 hours. The latter shall only apply to
eventualities involving unexpected major breakdown of HPWJ Pumps.
Under no circumstances will the tubesheet coating or tube ends be damaged by the HPWJ
cleaning. The Contractor shall establish a system or method to ensure impinging water jets
from the nozzle are not directly focused towards the tubesheet or onto the outside diameter of
the exposed tube ends. Prior to any HPWJ cleaning activities and inspection shall be
performed by the Contractor supervisor and the Engineer to record the existing condition of
the tubesheet and tube ends. This activity shall be included in the QCP as a hold point. Any
damage to coating will be for contractor’s expense to repair; Eskom’s coating standard [3]
shall be applied for any coating repairs.
The Contractor shall make provision of adequate number of hand held pneumatic powered
feeders.

The Contractor’s selection of all lances, nozzles, sleeves and hosing shall be suitable for the
tubing diameters as defined by site.
The endoscope used for inspection of the tubes after HPWJ shall have a minimum length of
6m and a camera with minimum specifications.

2.1.3 COMMISSIONING TESTS AND OPTIMIZATION

Before any work is performed the Contractor shall demonstrate the following to the Engineer:
Provide all required certificates (equipment pressure tests, pressure gauge calibration,
personnel training).
The Engineer shall verify that the equipment on site complies in all respects to the technical
data sheets provided with the tender as well as that the number of pumps, hoses, foot valves,
cleaning nozzles, etc. on site corresponds in all respects to the information provided in the
tender returnables.
The Contractor shall demonstrate to the Engineer that the HPWJ pump, hose and nozzle
combination can supply a volume flow rate of 50litre/min by means of a container and
stopwatch method for a pump outlet pressure of 1000 bar.
The Contractor shall demonstrate that the lance safety device (with a hand held pneumatic
powered feeder) prevents the lance from withdrawing from the tube during HPWJ and hence
is safe for operators.

Before starting with the production cleaning activity the contractor in consultation with the
engineer shall establish an acceptable nozzle resident/dwell time (cleaning a minimum of 10
tubes) demonstrating the capability of meeting the acceptance criteria. During cleanliness
sampling inspections, it may be found that cleaning with the pre-established nozzle
resident/dwell time is ineffective (scale not being entirely removed). In such an event the
nozzle resident/dwell time may be further increased by virtue of a 10 tube cleaning test. This
shall only be performed in consultation with the engineer, and actual high definition
endoscope inspections of ‘cleaned tube sections”
If available, the Engineer shall provide the contractor with a short piece, typically 1m, of new
condenser tube of the same material of construction as that in the condenser or heat exchanger
The Contractor shall demonstrate to the Engineer that the working pressure and cleaning
nozzle combination does not damage the tube internal surface.
2.1.4 ADDITIONAL REQUIREMENTS

The Contractor shall supply suitable Endoscope/Fiberscope equipment to facilitate post

cleaning inspection. The fibre scope shall have a reach length of at least 6 m with a digital
display that includes image capture and/or and recording capabilities.
The Contractor shall supply and install suitable protection or covers on the main cooling
water inlet duct to eliminate any of the debris removed from the condenser tube falling down
the CW inlet duct.
The Contractor shall compile a final method statement, safety work procedure and Quality
Control Plan (QCP) and submit these to the Engineer for approval before cleaning may
commence. The Engineer shall have the opportunity to add witness or hold points on the
QCP.
All tubes which are blocked or obstructed and which cannot be unblocked by HPWJ shall be
marked on the tubesheet drawing.
The Contractor shall maintain a daily logbook where the number of tubes cleaned, working
pressures, etc. are logged.
As stated above the minimum acceptance criteria is that all scale shall be removed from the
internal surface of the tubes, i.e. the entire internal tube surface of all the tubes shall be
completely clean with no traces of corrosion product or other scales and deposits on the tube
inner surfaces.
The Contractor shall clean the waterboxes and drain pipes connected to waterboxes after
cleaning the tubes. All foreign materials and debris shall be removed from the waterboxes by
the contractor.

3. SCOPE OF WORK (SOW)

The generic SOW includes but not limited to the following:

 Condenser tubes
 Oil pipes
 Generator coolers
 Main oil coolers
 Seal oil coolers
 Lube oil cooler
 Control oil system
 Stator water tubes
 Exciter coolers
 Plate heat exchangers
 Lubrication oil returns line
 Seal oil return line
 Lubrication and seal oil pump suction lines (AOP, AC –lube and seal oil, DC – lube
and seal oil)
 Main Oil Tank drain line (Coalescer suction line)
 Provision to be made for ERI Works for high pressure cleaning (Once a year)

4. SAFETY REQUIREMENTS

The safety of the Contractor personnel is of extreme importance. The following are the
minimum safety requirements that the HPWJ operators shall comply to:
 Operators shall wear CE (European Economic Area Conformity Marking) certified
water jetting suits, and face shields rated for the working pressure stated in section
3.4.
  All foot and leg protection equipment to be appropriately rated for the working
pressure stated in section 3.4.
 The Contractor shall work in accordance with a safety procedure/instruction aligned
to industry recognised HPWJ practices and standards to protect personnel using
HPWJ equipment.
 HPWJ operators shall be trained and certified by an independent industry recognised
HPWJ authority. No operator will be allowed to use HPWJ lances on site without the
required certification.
 All HPWJ hoses and associated equipment and tooling, i.e. nozzles, fittings, foot
valve, used on site shall have valid pressure test certificates. The test pressure shall be
a minimum of 1 400 bar.
 All hose end connections to be fitted with the appropriate “hose checks” to prevent
injury by restraining the hose in the event of an end fitting failure.
 The HPWJ pump discharge shall be fitted with a calibrated pressure gauge and safety
relief valve or rupture diaphragm.
 Any manholes which are open for ventilation purposes shall be properly barricaded
by the Contractor to eliminate unauthorised human entry while cleaning is in
progress.
 Barriers and Warning notices must be in place before any work commences
 Specific requirements related to Eskom’s “Life Saving Rules” that would be
applicable to this activity.

5. SHEQ REQUIREMENTS

All service providers are expected to comply with, but not limited to the following:

 Compliance with the Occupational Health and Safety Act 85 of 1993 is compulsory.
 Adherence to Quality Management System Policies, Procedures and related
requirements of ISO 9001.
 Adherence to Occupational Health and Safety Policies, Procedures and related
requirements of the OHSAS 18001.
 Adherence to environmental aspects, related impacts and legal requirements associated
with work activities in accordance with ISO 14001.
 Adherence to Life Saving Rules.
 Compliance with the Eskom Plant Safety Regulations.
 Only authorised documents and processes are to be used in the execution of duties.
 Continuously seek methods for improvements from a process, quality and safety
perspective.
 Obey all instructions.
 Familiarize with:
 The applicable work instructions and procedures in place.
 Safe working conditions and procedures.
 All legal and contractual requirements.
 Discipline and integrity.
  Compliance to all ERI Work Instructions, processes, procedures, and standards
 Adherence to ERI’s disciplinary code or practice.
 Set example to co-workers and others.
 Participate in Risk Assessments.
 Responsible for own safety.
 Responsible for Personal Protective Equipment issued.
 Execute duties promptly and safely.
 Safeguard tools and safety equipment issued.
 Keep good relationship with all personnel.
 Compile a HIRA for each and every activity that needs to be performed.
 Ensure the activities are carried out following a Works Instructions and Procedure.
 Adhere to clean condition policy where required.
 All activities to be carried out as per the documented processes and comply with the
requirements of ISO and OHSAS certification
 Service provider to comply to Eskom PPE (Personal Protective Equipment) Policy
with regards to issuing of PPE to resources
 Proper use of PPE to be followed
 Ensure that tools and equipment are stored correctly in a safe place.

6. KEY PERFORMANCE INDICATORS

Key Performance Unit of Source of
Objective Measure
Indicator Measure Evidence
Safety Sustainability LTI Free days LTI Free days Days To be provided by supplier
Available within 24 Number of queries
Turnaround Time Nr To be provided by supplier
hours responded to
Due Date Average contracted To be provided by supplier
Due Date Performance Days
Performance outage days
Reduce the Number of No of Rework Number of Rework To be provided by supplier
Nr
Rework Incidents Incidents Incidents
Rework Duration Number of Days To be provided by supplier
Reduce the Rework (Days additional to Rework Duration
Days
Duration planned outage Impacts Outage Due
duration) Date
No of Legal & No of Legal & To be provided by supplier
Number of
Environmental Environmental Nr
contraventions
Contraventions Contraventions
Zero Fatalities To be provided by supplier
Zero Fatalities
Excl 3rd party at Number of fatalities Nr
Excl 3rd party at fault
fault
 7. TECHNICAL EVALUATION

SUPPLY OF HIGH PRESSURE CLEANING Weight

1 Experience on successfully completed power plant High Pressure Cleaning 50

Provide copies of formal contract(s) OR purchase orders(s) executed anytime in the past
two financial years up to current date - (evidence to be on client letterhead, reflecting
period i.e. start and end date strictly, value/amount, type of service
1.1 No evidence submitted = 0 30
Less than R2m = 10
Between R2m and R5m = 20
Above R5m = 30

Reference letter(s) / Completion Certificate of satisfaction from previous client(s)

No evidence = 0
1.2 20
Four letter submitted = 10
5 and above letters = 20
2 Resources – key assigned personnel 10

CVs of assigned personnel

2 x Supervisors with more than two years verifiable High Pressure Cleaning
supervision experience. The cv must indicate exactly where, when and how long
2.1. 10
No evidence = 0
2 CVs submitted = 10
3 Equipment 20
Asset register or lease agreement displaying items, asset registration number and proof of
maintenance (old) or maintenance plan for new or leased items. Items refer to main High
3.1
Pressure Cleaning equipment

Asset register or lease agreement

No evidence = 0
20
Asset register with pictures / video submitted = 10
Asset register with pictures / video submitted with proof of maintenance plan = 10
4 Method Statement and Safe Working Procedure 20
4.1 Preliminary method statement for cleaning the heat exchanger/condenser tubes/Oil pipes
Safe Working Procedure
Method statement and Safe Working Procedure 20
No evidence = 0
Partial submission – Method Statement and Safe Working Procedure = 10
Full submission – Method Statement and Safe Working Procedure = 20
TOTAL 100

Minimum qualifying criteria = 70%